Wall Forms for Spraying Insulation

ABSTRACT

A panel system is provided to form a barrier and an enclosed cavity for spraying foam insulation. The panel system may use panel sections removably attached together to achieve a desired length. The panel sections are attached to wall studs and foam insulation is sprayed into the resulting cavity. After the foam has reacted, the panels may be removed and reused in another section. In one embodiment, a plastic sheet is used as a barrier between the panel and the foam insulation, which sheet can later be removed.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. provisional patent application No. 60/767337, filed Mar. 20, 2006.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH

Not Applicable.

APPENDIX

Not Applicable.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention

2. Related Art

Spraying foam insulation is a complicated process. The foam ingredients must be mixed, heated, and then pressurized. The foam is then sprayed onto walls to fill various areas such as gaps, cracks, and spaces between wall studs.

When the foam is sprayed onto a surface, the foam begins to expand. After drying, the dried foam is trimmed flush to various surfaces. For example, when foam is sprayed between wall studs, the dried foam is trimmed so that the outer surface of the foam is flush with the outer surface of a wall stud.

The trimming operation takes time in the form of trimming time, and cleanup time in collecting the trimmed waste.

SUMMARY OF THE INVENTION

The present invention is a panel system that enables foam insulation to be sprayed in a way that minimizes trimming and waste. In the invention, a panel section is provided that is used to contain an open space between wall sections. Optionally, a plastic sheet may be used for attaching across the open face of a cavity to serve as a barrier between the spray foam insulation and a panel.

Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:

FIG. 1 is a front view of the panel of the present invention;

FIG. 2 is a side view of the panel of the present invention;

FIG. 3 is an elevated view of an inside corner of a house;

FIG. 4 is an elevated view of the placement of panels into an inside corner of FIG. 3;

FIG. 5 is an elevated view of retaining means being applied to the panels of FIG. 4;

FIG. 6 is an elevated view of screws being applied to the panels of FIG. 4;

FIG. 7 is an elevated assembly view of a plastic sheet and panel, as applied to the corner of FIG. 4;

FIG. 8 is a perspective view of an alternative panel embodiment; and

FIG. 9 is a perspective view of an alternative panel embodiment of the panel in FIG. 8.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.

In FIG. 1, a panel shown generally at 10 is provided. Preferably, the panel has a width that corresponds to standard widths between studs, namely, 12, 18, 24 32 and 48 inches.

Panel 10 comprises a panel frame 14. Panel frame 14 is preferably made from flat aluminum or metal strips. Between the strips of panel frame 14, a mesh 16 is provided. Panel 10 is preferably provided with handle 18 for ease of handling. Preferably, panel 10 may be 96 inches in length, although it is recognized that panel length will vary according to need.

It will be appreciated that panel 10, for practical reasons, will come in various standard lengths. These lengths may be cumbersome for storage and transportation. Accordingly, these panels may be provided with means for combining multiple sections together. In the present invention, these panel sections may be provided with a hinge section, whereby multiple sections can be removably and pivotably attached by a hinge. For travel and storage, the hinge pin can be removed, and the sections can be more easily stored and carried.

The panel 10 is used in combination with plastic sheet 20, to form a cavity between a wall and studs. In essence, the panel 10 and plastic sheet 20 form a barrier to prevent spray foam insulation from expanding past the surface of wall studs. First, as shown in FIG. 3, plastic sheeting 20 is attached to wall framing and studs 22.

Next, panel 10 is removably attached to wall stud using screws and a drill. In particular, wood or some other suitable material may be used as shown in FIGS. 5-6 as a base 24 for applying screws 26 through the base 24, through the panel mesh 16, through plastic sheet 20, and through wall stud 22. Multiple panels 10 are butted together.

The cavity formed by panels 10 and wall studs 22 is then filled with spray foam. In particular, the tip of a foam spray gun (not shown) may be inserted through a hole in the mesh 16, and punched through plastic sheet 20. The plastic sheet 20 is used as a non-adhering barrier between the panel 10 and the sprayed foam insulation.

After the spray foam insulation has reacted and filled the cavity, the panels 10 may be removed. Then, plastic sheet 20 may be removed at any time and discarded. Plastic sheet 20 is preferably removed by pulling one edge of the sheet.

Then, the process repeats by applying new plastic sheeting 20 to an uninsulated wall section, and removably attaching the old panels to wall studs to form additional cavities. Next, the process of filling the cavity with spray foam insulation is repeated.

After the plastic sheet is removed, the open foamed surface remains. This surface may be finished by brushing with a wire brush.

In an alternative embodiment shown in FIGS. 8 and 9, panel 10 may be made in sections from a smooth plastic, and provided with holes 40. In this alternative embodiment, panel 10 is made in a unit form. Multiple panel 10 units may be pieced together to form a long panel length by inserting screws (not shown) through holes 40. Then, holes 42 in tab 44 are used to fix panel 10 to wall stud. FIG. 9 shows an alternative panel 10, similar to the panel 10 in FIG. 8, wherein an additional lip 46 is provided to provide a more secure fit with wall stud 22. It is important to note that holes 40 at the top end (relative to an installed panel 10) may also serve as an access point for the insertion of the foam gun tip, although an additional hole (not shown) may also be provided for that purpose.

In use, in the alternative embodiments, no plastic sheet is used. Instead, the plastic panel 10 is applied directly to the wall stud 22 by applying a screw through hole 42 in tab 44. Then, the foam is applied through hole 40, or a different hole provided for this purpose, and the cavity is filled with foam insulation. After the foam has reacted, panel 10 may be removed and re-used by repeating the above process.

As various modifications could be made to the exemplary embodiments, as described above with reference to the corresponding illustrations, without departing from the scope of the invention, it is intended that all matter contained in the foregoing description and shown in the accompanying drawings shall be interpreted as illustrative rather than limiting. For example, it should be appreciated that various dimensions of the various parts of the panel will necessarily vary according to need and the availability of materials. Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims appended hereto and their equivalents. 

1. A panel for spray foam insulation comprising: a first panel section adapted for attachment to a wall stud; a second panel section adapted for attachment to a wall stud; wherein said first panel section is removably attached to said second section.
 2. A panel for spray foam insulation according to claim 1, wherein said first panel section further comprises: a hole adapted for insertion of a tip of a spray foam gun.
 3. A panel for spray foam insulation according to claim 1, wherein said first panel section is removably attached to said second panel section using screws.
 4. A panel for spray foam insulation according to claim 1, wherein said first panel section further comprises: a frame; and mesh attached to said frame.
 5. A panel for spray foam insulation according to claim 1, wherein said first panel section further comprises: a plastic panel; and a plurality of tabs extending from said plastic panel.
 6. A method for using panels for spray foam insulation comprising: attaching a first panel section to a second panel section to form a resultant panel section; attaching said resultant panel section to a wall section; inserting a tip of a spray gun through said resultant panel; and applying foam through said spray gun.
 7. A method according to claim 4, further comprising: attaching a plastic sheet to a wall section before said step of attached said resultant panel section to a wall section; and inserting a tip of a spray gun through said plastic sheet panel after said step of inserting a tip of a spray gun through said resultant panel.
 8. A method according to claim 4, wherein said step of attaching said resultant panel section to a wall section comprises screwing said resultant panel section to a wall section.
 9. A method according to claim 4, wherein said step of attaching said resultant panel section to a wall section comprises disposing a base across said resultant panel section and inserting screws through said base to said wall section. 